Apparatus for Making Window Screen Sash

ABSTRACT

A screen frame is made by joining four or more straight frame pieces and four corner pieces to one another in a square or rectangular shape. Each straight frame piece and each corner piece have an outboard part and an inboard part with a channel formed in it. The outboard part of each straight frame piece is hollow and has an aperture formed in its opposite ends. Each corner piece includes an apertured protuberance at opposite ends of its outboard part. An alternative embodiment adds a plurality of extension members that may be coupled to the straight frame members. Each extension member has an apertured protuberance formed in a first end of its hollow outboard part and an aperture formed in a second end of its hollow outboard part.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to currently pending U.S. provisionalpatent application 60/720,077, entitled, “Adjustable Window Screen,”filed Sep. 23, 2005, which application is hereby fully incorporatedhereinto by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of window screen repairs. Moreparticularly, it relates to an apparatus that enables a homeowner tomake window screen sashes.

2. Description of the Prior Art

Many consumers in need of a new window screen frame, known in theindustry as a window screen sash, will contact a screening contractor.The contractor must go to the consumer's home to measure the size ofeach window to be screened. The contractor then returns to his or herplace of business to make the needed frames or to place an order for theneeded frames to be manufactured. When the frames have beenmanufactured, then the contractor must return to the site forinstallation. Thus, the contractor makes two (2) trips to the consumer'shouse. This adds to the cost of the final installation.

Many consumers choose to do the job themselves to save money. Theypurchase long aluminum frame pieces from a home improvement store,measure their windows, and cut the frame pieces to size with a hacksaw.

Some consumers are not handy with a measuring tape, and do a poor job ofmeasuring the windows. Some consumers lack hacksaw skills, and do a poorjob of cutting the frames to size. Any mistake in measurement or incutting can result in a need to do the job a second time, again addingto the cost of the final installation.

Thus there is a need for an apparatus that eliminates the need to hire ascreen contractor, and which does not require a homeowner to measurewindows and cut long frames to size.

There is also a need for an apparatus that can be adjusted to fit awindow so that the size of the window need not be measured with a highdegree of precision.

However, in view of the prior art considered as a whole at the time thepresent invention was made, it was not obvious to those of ordinaryskill in this art how the identified needs could be met.

SUMMARY OF INVENTION

The long-standing but heretofore unfulfilled need for a window screensash construction that does not require the hiring of a contractor andthat involves no cutting of parts is now provided in the form of anapparatus that includes at least four straight frame pieces, at leasttwo (2) extension pieces, and at least four (4) corner pieces to form asquare or rectangular window screen frame. All components are preferablyformed of a strong, durable plastic. Other suitable materials are withinthe scope of this invention.

More particularly, a first embodiment of the novel apparatus includes aplurality of straight frame members and a plurality of corner members.Each straight frame member of said plurality of straight frame membershas an outboard part of hollow construction formed integrally with aninboard part having a channel formed therein. Each straight frame memberhas a first aperture formed in a first end of the outboard part and asecond aperture formed in a second end of the outboard part.

Each corner member of the plurality of corner members has an “L”-shapedoutboard part formed integrally with an “L”-shaped inboard part having achannel formed therein. A first apertured protuberance is formed in afirst end of the outboard part of each corner member and a secondapertured protuberance is formed in a second end of the outboard part ofeach corner member.

A plurality of pins is adapted to be positioned in the apertures thatare aligned with one another when the various parts are in theirrespective operative positions.

In the first embodiment, the sash or frame is formed by interconnectinga plurality of the straight frame members and a plurality of the cornersmembers into a square or rectangular configuration by insertingrespective protuberances of the corner members into respective hollowinteriors of the outboard parts of the straight frame members so thatthe respective outboard and inboard parts of the straight frame membersand the corner members are in alignment with one another, so thatrespective apertures formed in the protuberances of the outboard partsof the corner members are in alignment with respective apertures formedin the outboard parts of the straight frame members, so that therespective apertures formed in the outboard parts of the straight framemembers are in alignment with respective apertures formed in theprotuberances of the corner parts, and so that the respective aperturesare maintained in alignment with one another by respective pins of saidplurality of pins.

In a second embodiment, a plurality of extension members is provided tolengthen the effective length of the straight frame pieces. Eachextension member of the plurality of extension members has an outboardpart of hollow construction integrally formed with an inboard parthaving a channel formed therein. Each extension member has an aperturedprotuberance formed in a first end of its outboard part and eachextension member has an aperture formed in a second end of its outboardpart.

An extension member is connected to a straight frame member by insertingan apertured protuberance formed in the first end of the extensionmember into a hollow interior of the outboard part of the straight framemember so that the aperture formed in the protuberance of the extensionmember is aligned with an aperture formed in the outboard part of thestraight frame member.

The aperture formed in the protuberance of the extension member and theaperture formed in the outboard part of the straight frame member aremaintained in the alignment with a pin of said plurality of pins.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the invention, reference should be made tothe following detailed description, taken in connection with theaccompanying drawings, in which:

FIG. 1 is a plan view of a straight frame piece;

FIG. 2 is a plan view of an extension piece; and

FIG. 3 is a plan view of a corner piece.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, it will there be seen that a straight framepiece that forms a part of the invention is denoted as a whole by thereference numeral 10. At least four (4) of said straight frame piecesare required to make a square or rectangular frame (sash) for a screen.The straight frame pieces are provided to the consumer in differinglengths but they are whole and complete as sold. Unlike prior art framepieces, they are not cut to length by the consumer to fit a particularjob.

Each straight frame piece 10 includes outboard part 12 and inboard part14 that is formed integrally with outboard part 12. Outboard part 12 isof hollow construction. Channel 16 is formed in inboard part 14 and isadapted to receive therein the peripheral edge of a screen, notdepicted. The peripheral edge is maintained in channel 16 by an elongatevinyl spline, not depicted, that is squeezed into channel 16 inoverlying relation to the screen by a well-known roller tool, notdepicted.

A first aperture 18 is formed in outboard part 12 at a first end thereofand a second aperture 20 is formed in outboard part 12 at a second endthereof

FIG. 2 depicts novel extension piece 22. It is also provided in variouslengths but has essentially the same width as straight frame piece 10.Extension piece 22 is also whole and complete as sold to the consumerand is not cut by the consumer. It includes hollow outboard part 24,inboard part 26 formed integrally with outboard part 24, and channel 28formed in said inboard part. Protuberance 30 extends from a first end ofoutboard part 24, and aperture 32 is formed in said protuberance. Noprotuberance is formed on the second end of outboard part 24. Aperture34 is formed in the second end of outboard part 24.

FIG. 3 depicts corner piece 36 having “L”-shaped outboard part 38 and“L”-shaped inboard part 40 formed integrally therewith. Corner piece 36has an “L”-shape, so that outboard part 38 has a first section 38 a anda second section 38 b, formed integrally with first section 38 a, thatis disposed at a ninety degree angle relative to said first section 38a. Similarly, inboard part 40 has a first section 40 a and a secondsection 40 b, formed integrally with first section 40 a, that isdisposed at a ninety degree angle relative to said first section 40 a. Afirst channel is formed in first part 40 a and a second channel isformed in second part 40 b. Said channels are adapted to snugly receivethe peripheral edge of a screen and a vinyl spline that overlies saidperipheral edge in a well-known way.

Protuberance 42 is formed in a first end of outboard section 38 a and isapertured as at 44. Protuberance 46 is formed in the second end ofoutboard section 38 b and is apertured as at 48.

A frame, known in the window-screen industry as a sash, may be assembledfrom four (4) straight frame pieces 10 and four (4) corner pieces 36.For example, apertured protrusion 46 of corner piece 36 is slideablyinserted into the hollow interior of the second end of outboard part 12of straight frame piece 10 so that apertures 48 and 20 are in alignmentwith one another. Such arrangement also aligns channel 40 b of cornerpiece 36 with channel 16 of straight frame piece 10. A pin, notdepicted, is then snugly placed through apertures 48 and 20 to lockcorner piece 36 onto said straight frame piece 10. The three remainingcorner pieces and straight frame pieces are assembled in a similar way,with the pieces being oriented so that the respective aperturedprotuberances of the corner pieces are received within the hollowinteriors of the respective outboard parts of the straight frame piecesand so that the respective channels are in alignment with one another.

In the alternative, a sash may also be made by augmenting the aboveconstruction with two, four, or higher even numbers of extension pieces22. For example, the length of straight frame piece 10 may beeffectively lengthened by inserting apertured protuberance 32 ofextension piece 22 into the hollow interior of the second end ofoutboard part 12 of straight frame piece 10 so that apertures 32 and 20are in alignment with one another. A pin is then extended through saidaligned apertures to lock the respective positions of straight framepiece 10 and extension piece 22.

A second extension piece 22 is added if still further length is requiredby inserting apertured protuberance 32 of a second extension piece 22into the hollow interior of the second end of the outboard part of thefirst extension piece 32 so that aperture 32 of the second extensionpiece aligns with aperture 34 of the first extension piece, and againemploying a pin to lock the first and second extension pieces together.

If no third extension piece is required to be connected to the firststraight frame piece 10, apertured protrusion 46 of a corner piece 36 isinserted into the hollow interior of the outboard part of the second endof the second extension piece 22 until apertures 34 and 48 are aligned.Another pin is then employed.

In this way, any even number of extension pieces 22 may be added to astraight frame piece 10 as needed in a particular application toincrease the effective width or length of the sash. Completion of thesash requires the use of four (4) corner pieces 36 in the mannerdescribed.

When the screen and vinyl spline are in place, the vinyl spline acts asan additional reinforcement means for keeping all the parts together.

It will be seen that the advantages set forth above, and those madeapparent from the foregoing description, are efficiently attained andsince certain changes may be made in the above construction withoutdeparting from the scope of the invention, it is intended that allmatters contained in the foregoing description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed, and all statements of the scope of the invention which, as amatter of language, might be said to fall therebetween. Now that theinvention has been described,

1. An apparatus for making a frame for a screen, comprising: a pluralityof straight frame members; each straight frame member of said pluralityof straight frame members having an outboard part of hollow constructionformed integrally with an inboard part having a channel formed therein;each straight frame member having a first aperture formed in a first endof said outboard part and a second aperture formed in a second end ofsaid outboard part.
 2. The apparatus of claim 1, further comprising: aplurality of corner members; each corner member of said plurality ofcorner members having an “L”-shaped outboard part formed integrally withan “L”-shaped inboard part having a channel formed therein; a firstapertured protuberance formed in a first end of the outboard part ofeach corner member; and a second apertured protuberance formed in asecond end of the outboard part of each corner member.
 3. The apparatusof claim 2, further comprising: a plurality of pins adapted to bepositioned in respective apertures formed in said straight frame membersand said corner members when said straight frame members and cornermembers are cooperatively connected to one another to form said framefor a screen; whereby said frame is formed by interconnecting aplurality of said straight frame members and a plurality of said cornersmembers into a square or rectangular configuration by insertingrespective protuberances of said corner members into respective hollowinteriors of said outboard parts of said straight frame members so thatthe respective outboard and inboard parts of said straight frame membersand said corner members are in cooperative alignment with one another,so that respective apertures formed in said protuberances of saidoutboard parts of said corner members are in alignment with respectiveapertures formed in said outboard parts of said straight frame members,and so that said respective apertures are maintained in alignment withone another by respective pins of said plurality of pins.
 4. The frameof claim 1, further comprising: a plurality of extension members; eachextension member of said plurality of extension members having anoutboard part of hollow construction integrally formed with an inboardpart having a channel formed therein; each extension member having anapertured protuberance formed in a first end of its outboard part; eachextension member including an aperture formed in a second end of itsoutboard part; a plurality of pins adapted to be positioned inrespective apertures formed in said straight frame members and saidextension members when said straight frame members and extension membersare cooperatively connected to one another to form said frame for ascreen; whereby an extension member is connected to a straight framemember by inserting said apertured protuberance formed in said first endof said extension member into a hollow interior of said outboard part ofsaid straight frame member so that said aperture formed in saidprotuberance of said extension member is aligned with an aperture formedin said outboard part of said straight frame member; whereby saidaperture formed in said protuberance of said extension member and saidaperture formed in said outboard part of said straight frame member aremaintained in said alignment with a pin of said plurality of pins.